Packaging system including a multi-component base structure

ABSTRACT

A pallet base structure including a center deck defining a support surface extending between opposed sides and having at least two lugs extending from each of the opposed sides. A pair of base side members are positioned along respective sides of the center deck. Each base side member has first and second spaced apart base legs and a support member extending between the base legs with at least two corresponding lug receiving slots defined in the support member. The respective lugs are received in the respective lug receiving slots such that the center deck support surface is aligned with an upper surface of each support member to define a planar pallet surface. A packaging system incorporating the pallet base structure is also described.

This application claims the benefit of U.S. Provisional Appln. No.61/665,336 filed on Jun. 28, 2012, the contents of which areincorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to a packaging system for moving freestandingdevices. In particular, this invention relates to a packaging systemincluding a multi-component base structure with a center deck configuredsuch that it can be utilized to support the freestanding device duringmovement.

BACKGROUND OF THE INVENTION

Freestanding devices are utilized in many industries. The devicesinclude a housing supported on a number of legs, typically four, whichdepend from the housing. The housing encloses equipment for a givenapplication, for example, food or beverage vending equipment, computerkiosks, automated teller assemblies, or rental equipment as a fewexamples. A specific example is a freestyle fountain vending machinewhich has a beverage dispenser, touch-screen input, computer controller,and fountain beverages all housed within the housing. FIGS. 1-4illustrate two exemplary freestyle fountain vending machines packagedwithin a packaging system in accordance with the present invention. Theexemplary freestyle fountain vending machines each include four legs(not shown) which support the housing a given distance off the floor orother support system.

The freestanding devices are typically manufactured by a manufacturer ina manufacturing facility with all of the equipment assembled into thehousing such that the device requires minimal setup once delivered to ause location. Additionally, the housing is often finished with a desiredlook, for example, company branding or matching the decor of the uselocation. The freestanding device is delivered from the manufacturingfacility to the use location, is set in position, and final connections,for example connection to a power supply and/or network, are made toactivate the device.

Since the housing is often finished and houses potentially delicateequipment, it is desirable to deliver the freestanding device in asecure manner which protects the housing and the equipment insidethereof. It is also desirable to utilize packaging which allows easytransport of the device. It is further desirable to utilize packagingwhich is easy to remove without significant effort.

SUMMARY OF THE INVENTION

Briefly, the present invention provides a packaging system including amulti-component base structure with a center deck configured such thatit can be utilized to support the freestanding device during movement.

In one aspect, the invention provides a pallet base structure includinga center deck defining a support surface extending between opposed sidesand having at least two lugs extending from each of the opposed sides. Apair of base side members are positioned along respective sides of thecenter deck. Each base side member has first and second spaced apartbase legs and a support member extending between the base legs with atleast two corresponding lug receiving slots defined in the supportmember. The respective lugs are received in the respective lug receivingslots such that the center deck support surface is aligned with an uppersurface of each support member to define a planar pallet surface.

In another aspect, the invention provides a packaging systemincorporating a pallet base structure including a center deck defining asupport surface extending between opposed sides and having at least twolugs extending from each of the opposed sides. A pair of base sidemembers are positioned along respective sides of the center deck. Eachbase side member has first and second spaced apart base legs and asupport member extending between the base legs with at least twocorresponding lug receiving slots defined in the support member. Therespective lugs are received in the respective lug receiving slots suchthat the center deck support surface is aligned with an upper surface ofeach support member to define a planar pallet surface. A cover member isconfigured to be positioned spaced from the pallet base structure and atleast one strap member is configured to extend about the pallet basestructure and the cover member such that the pallet base structure andthe cover member are an interconnected unit.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitutepart of this specification, illustrate the presently preferredembodiments of the invention, and, together with the general descriptiongiven above and the detailed description given below, serve to explainthe features of the invention. In the drawings:

FIG. 1 is a front elevation view of a packaging system in accordancewith an embodiment of the present invention positioned about anexemplary freestanding device.

FIG. 2 is a side elevation view of the assembly of FIG. 1.

FIG. 3 is a front elevation view of a packaging system in accordancewith an embodiment of the present invention positioned about anotherexemplary freestanding device.

FIG. 4 is a side elevation view of the assembly of FIG. 3.

FIG. 5 is a perspective view of an exemplary base center deck inaccordance with an embodiment of the invention.

FIG. 6 is a top plan view of the exemplary base center deck of FIG. 5.

FIG. 7 is a left side elevation view of the exemplary base center deckof FIG. 5.

FIG. 8 is a front elevation view of the exemplary base center deck ofFIG. 5.

FIG. 9 is a perspective view of an exemplary right base side member inaccordance with an embodiment of the invention.

FIG. 10 is an elevation view of the exemplary right base side member ofFIG. 9.

FIG. 11 is a top plan view of the exemplary right base side member ofFIG. 9.

FIG. 12 is a bottom plan view of the exemplary right base side member ofFIG. 9.

FIG. 13 is a perspective view of an exemplary cover member in accordancewith an embodiment of the invention.

FIG. 14 is a top plan view of the exemplary cover member of FIG. 13.

FIG. 15 is a side elevation view of the exemplary cover member of FIG.13.

FIG. 16 is a front elevation view illustrating positioning of theexemplary base center deck relative to the exemplary base side members.

FIG. 17 is a front elevation view similar to FIG. 16 and illustratingthe base center deck and the freestanding device thereon positionedrelative to the base side members.

FIG. 18 is a front elevation view similar to FIG. 16 illustratingremoval of the base side members.

FIG. 19 is a perspective view illustrating an assembled packaging systemin accordance with an embodiment of the invention.

FIGS. 20-23 are perspective views similar to FIG. 19 illustrating thesequential disassembly of the packaging system relative to thefreestanding device positioned therein.

FIG. 24 a-24 h are top views illustrating sequential removal of the basecenter deck relative to the freestanding device legs in accordance withan exemplary embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

In the drawings, like numerals indicate like elements throughout.Certain terminology is used herein for convenience only and is not to betaken as a limitation on the present invention. For example, the termsfront, back, left and right are utilized herein to assist withunderstanding of relative positioning, but are not intended to belimiting to an orientation of use of the device. The following describesa preferred embodiment of the present invention. However, it should beunderstood, based on this disclosure, that the invention is not limitedby the preferred embodiment described herein.

Referring to FIGS. 1-4, an exemplary embodiment of a packaging system100 is shown positioned relative to exemplary freestanding devices 10,10′. The packaging system 100 of the present embodiment generallyincludes a base structure 110, a cover member 160 and a pair of straps190. In the illustrated assembled condition, the freestanding device 10,10′ is positioned with its legs (not shown) positioned within the basestructure 110 and the cover member 160 is positioned on top of thehousing 12, 12′. As shown, the housings 12, 12′ may have varyingconfigurations, with the base structure 110 and the cover member 160configured to correspond to the specific housing 12, 12′ structure. Thestraps 190 extend about the base structure 110 and the cover member 160and secure them as a unit in the assembled condition. As illustrated inFIGS. 1-4, the housing 12, 12′ preferably has a length and width lessthan that of the base structure 110 and cover member 160 such that thehousing 12, 12′ is recessed from the edges of the packaging system 100,thereby protecting the device 10, 10′ from bumps or the like duringtransport. As illustrated in FIGS. 20-23, wall structures 180 may alsobe utilized to further protect the devices 10, 10′ as described in moredetail hereinafter.

Referring to FIGS. 5-8, an exemplary base center deck 112 will bedescribed. The base center deck 112 includes side walls 113, 115extending between a front wall 114 and a rear wall 116. A series oflongitudinal and lateral ribs 117, 118 extend between the walls 113-116to define the deck structure. A pair of strap guide slots 120 extendalong the bottom surface of the deck 112 in the lateral direction. Therib structure is preferably manufactured from a polymeric material toprovide a light weight yet sufficiently strong structure, however, othermaterials may be utilized. Additionally, while the deck 112 isillustrated with an open rib structure, other structures, for example, asolid structure, a plank structure or a planar structure may beutilized. Similarly, while the exemplary deck 112 has a rectangularconfiguration, other configurations may be utilized.

A series of lugs 121 a, 123 a, 125 a extend from the left side wall 113and a series of lugs 121 b, 123 b, 125 b extend from the right side wall115. The lugs 121 a, 123 a, 125 a are configured to be received incorresponding slots 141, 143, 145 in the left base side member 130 a andthe lugs 121 b, 123 b, 125 b are configured to be received incorresponding slots 141, 143, 145 in the left base side member 130 b asdescribed in more detail below. The illustrated lugs 121, 123, 125 havea dovetail configuration, narrowing moving from the top surface of thedeck 112 toward the bottom surface thereof, however, they may have otherconfigurations. The lugs 121, 123, 125 have a height L which ispreferably less than the height H of the deck 112. While lugs andcorresponding receiving slots are described herein for releasablyinterconnecting the center deck 112 with the base members 130 a, 130 b,the invention is not limited to such and other releasable connectionmembers, for example, clamps, screws, pegs, dowels or the like may beused.

As indicated in FIG. 8, the deck 112 has a width w between the sidewalls 113, 115 which is less than the overall width W of the deck 112.The overall width W of the deck 112 is equal to the width w plus thedistance L the lugs 121-125 a, 121-125 b extend from the side walls 113,115. In the illustrated embodiment, the front lugs 121 a and 121 b arelongitudinally aligned while the mid lugs 123 a and 123 b arelongitudinally offset and the rear lugs 125 a and 125 are longitudinallyoffset. The relationship of the offsets and the widths w, W to theconfiguration of the device 10, 10′ will be described with reference toFIGS. 5-8 and 24 a-h.

FIG. 24 a illustrates the longitudinal position of the deck 112 relativeto the legs 14 a, 14 b of a freestanding device 10, 10′ as the deck 112would be positioned during transport. The legs 14 a on one side of thedevice 10, 10′ are laterally spaced from the legs 14 b on the oppositeside of the device 10, 10′ by a distance D as indicated in FIG. 24 h. Ina preferred embodiment, the distance D is smaller than the total widthW, but larger than the width w plus the distance L of one of the lugs121, 123, 125. With such a configuration, including the lug offsets, thedeck 112 provides as great as possible of a support width w while stillbeing slidable in a longitudinal direction to be removed from betweenthe legs 14 a, 14 b. Such slidability allows the center deck 112 to beremoved with the legs 14 a, 14 b already positioned on a supportsurface, i.e., the housing 12, 12′ does not have to be lifted to removethe center deck 112. Alternatively, the total width W can be made to besmaller than the distance D, whereby the deck 112 may be easily slid outfrom between the legs 14 a, 14 b, however, such a configuration reducesthe support width w of the center deck 112. It is noted that since theforward lugs 121 a, 121 b are already forward of the front legs 14 a, 14b, the lugs 121 a, 121 a of the illustrated embodiment arelongitudinally aligned without concern for passage between the legs 14a, 14 b.

Removal of the illustrated center deck 112 will be described withreference to FIGS. 24 a-24 h. In the initial step illustrated in FIG. 24a, the deck 112 is moved laterally such that the side 113 contacts thelegs 14 a. In this position, the opposite lugs 123 b and 125 b arelaterally clear of the legs 14 b. The deck 112 is moved forward asindicated by the arrow in FIG. 24 b until the mid lug 123 a contacts theforward leg 14 a. The deck 112 is then moved laterally as indicated bythe arrow in FIG. 24 c until the side 115 contacts the legs 14 b. Inthis position, the opposite lugs 123 a and 125 a are laterally clear ofthe legs 14 a. The deck 112 is moved forward as indicated by the arrowin FIG. 24 d until the mid lug 123 b contacts the forward leg 14 b, withthe lug 123 a clearing the legs 14 a. The deck 112 is then movedlaterally as indicated by the arrow in FIG. 24 e such that the side 113contacts the legs 14 a. In this position, the opposite lugs 123 b and125 b are laterally clear of the legs 14 b. The deck 112 is movedforward as indicated by the arrow in FIG. 24 f until the rear lug 125 acontacts the forward leg 14 a, with the lug 123 b clearing the legs 14b. The deck 112 is then moved laterally as indicated by the arrow inFIG. 24 g until the side 115 contacts the legs 14 b. In this position,the opposite lug 125 a is laterally clear of the legs 14 a. The deck 112is moved forward as indicated by the arrow in FIG. 24 h until the rearlug 125 b contacts the forward leg 14 b, with the lug 125 a clearing thelegs 14 a. With one last lateral movement and forward movement (notshown), the lug 125 b is clear of the legs 14 b and the center deck 112is removed. The center deck 112 is positioned under a device byreversing this procedure.

Referring to FIGS. 9-15, the base side members 130 and theinterconnection of the center deck 112 therewith will be described.FIGS. 9-12 show the right base side member 130 a, with the left baseside member 130 b preferably being a mirror image thereof. The base sidemember 130 includes a support member 132 extending longitudinally fromfront to back. The support member 123 is supported by a front base leg134 and a rear base leg 136 with a longitudinal space 133 therebetween.A bridge portion 131 of the support member 132 bridges between the legs134, 136 over the longitudinal space 133. Support strap slots 140 extendlaterally along the lower surface of the bridge portion 131 and areconfigured to longitudinally align with the strap slots 120 of the basecenter deck 112. The bridge portion 131 preferably has a height h whichis equal to a height H of the deck 112 to further align the slots 120,140. An upper wall 138 extends upward from the support member 132 alongthe side and rear edges thereof. The slots 140 may extend along theouter surface of the wall 138. As illustrated in FIG. 12, the supportmember 132, the base legs 134, 136 and the wall 138 are supported by aseries of lateral and longitudinal ribs 148, 149. Again, while a ribstructure is defined, the invention is not limited to such.

Each base side member 130 includes a series of lug receiving slots 141,143, 145 defined along the support member 132. The slots 141, 143, 145are longitudinally positioned such that they align with and receive therespective lugs 121 a, 123 a, 125 a or 121 b, 123 b, 125 b. Theillustrated slots 141, 143, 145 have a dovetail configurationcorresponding to that of the lugs 121, 123, 125, however, they may haveother configurations. The slots 141, 143, 145 have a depth such that thelugs 121, 123, 125 are received and stopped with the upper surface ofthe center deck 112 flush with the upper surface of the support member132.

A pair of leg receiving openings 135 and 137 are defined into thesupport member 132. Each opening 135, 137 is preferably longitudinallypositioned within a respective leg 134, 136 such that legs 14 receivedin the openings 135, 137 remain clear of the base side memberlongitudinal space 133. The openings 135, 137 are preferably taperedinward to assist in guiding the legs 14 into the openings 135, 137 whichalso assists in aligning the lugs 121, 123, 125 with the respectiveslots 141, 143, 145. As illustrated in FIGS. 13 and 14, the center deck112 is preferably positioned under the device housing 12, 12′ and liftedusing a pallet jack or the like. The base side members 130 a, 130 b aremoved into position relative to the raised housing 12, 12′ and legs 14,The upper wall 138 may contact the legs 14 to provide an initial macropositioning. As the center deck 112 is lowered, the legs 14 enter theopenings 135, 137 with the taper of the openings 135, 137 causing thebase side members 130 a, 130 b to move into a more precise alignment. Asthe deck 112 is continued to be lowered, the dovetail configuration ofthe slots 141, 143, 145 and the corresponding lugs 121, 123, 125 guidethe deck 112 into final mating position with the base side members 130a, 130 b. The deck 112 is lowered until the lugs 121, 123, 125 are fullyreceived in the slots 141, 143, 145 as illustrated in FIG. 14. Theopenings 135, 137 preferably have a depth approximately equal to theheight of the legs 14 such that the legs 14 contact the bottom of theopenings 135, 137 at the same time the housing 12, 12′ contacts theupper surface of the deck 112 and support members 132. The basestructure 110 is thereby fully assembled with a lateral space 153between the base side members 130 a, 130 b.

In this configuration, the device 10, 10′ may be moved by positioning apallet jack or the like laterally through the longitudinal opening 133,however, it is preferred that the cover member 160 is secured with thestraps 190 before movement. To remove the base structure 110 from thedevice 10, 10′, a pallet jack or the like is positioned longitudinallythrough the lateral opening 153 and the center deck 112 is lifted untilthe legs 14 clear the openings 135, 137, at which point the lugs 121,123, 125 have already cleared the slots 141, 143, 145, and the base sidemembers 130 a, 130 b are removed as indicated in FIG. 15. The centerdeck 112 is then lowered and removed in the manner described withreference to FIGS. 24 a-24 h.

Referring to FIGS. 9-11, the base side members 130 a, 130 b preferablydefine a wall receiving configuration. In this regard, an inner wallguide 146 extends upward from the bridge portion 131 opposite the upperwall 138 such that a wall receiving slot 139 is defined therebetween. Alower portion of a wall 180, see FIG. 21, is received within the slot139 and the inner wall guide 146 prevents the wall 180 from pressingagainst the device housing 12, 12′ when the straps 190 are attached.

Referring to FIGS. 13-15, the base side members 130 may be provided withshock dampeners 151 along the lower surface of each base leg 134, 136.Holes 147 may be provided in each base leg 134, 136 for securing thedampeners 151, although other connection mechanisms may be utilized. Theshock dampeners 151 have an elastomeric structure which helps to reduceshock and vibration experienced by the device 10, 10′ when beingtransported. The shock dampeners 151 may have various configurations,for example, they may be solid structures manufactured from anelastomeric material or fluid filled which is either sealed or fillable.Referring to FIGS. 9-11, in the illustrated embodiment, the upper wall138 includes recesses 142, 144 configured to receive the shock dampeners151 of a base side member 130 which may be stacked thereon, for example,during storage.

Referring to FIGS. 16-18, an exemplary cover member 160 will bedescribed. The exemplary cover member 160 includes a planar portion 162with a raised center portion 163. The raised center portion 163 definesa concave internal space 165 configured to receive the upper portion ofthe device housing 12, 12′. The raised center portion 163 may have astepped configuration to facilitate use with different housingconfigurations. A pair of strap slots 170 extend laterally across theraised center portion 163 and are positioned to align with the strapslots 120, 140 upon assembly.

A rim 164 depends from the perimeter of the planar portion 162, with thelateral sides of the rim 164 defining an extended portion 166. Insidethe extended portion 166, a number of wall projections 168 extend fromthe inside surface of the planar portion 162 such that a wall receivingslot 169 is defined between the projections 168 and the inside surfaceof the extended portion 166. An upper portion of the wall 180, see FIG.21, is received within the slot 169.

When a freestanding device 10, 10′ is ready for transport, the device isfirst positioned with respect to the base structure 110 as describedwith reference to FIGS. 13 and 14. If utilized, the wall 180 ispositioned such that the lower portion of the wall 180 is received inthe slots 139 defined by the base side members 130. The cover member 160is then positioned on top of the device housing 12, 12′ with the upperportion thereof received in the concave internal space 165 and the upperportion of the wall 180 is received within the slot 169. Straps 190 aresecured around the base structure 110 and the cover member 160, receivedin the respective slots 120, 140, 170. The freestanding device isthereby secured within the packaging system 100 as illustrated in FIG.19. The device can be delivered with reduced chance of damage and can bemoved proximate to its final use location via a pallet jack positionedthrough the lateral space 153.

Once delivered, the freestanding device 10, 10′ may be easily unpackedfrom the packaging system 100 in the manner illustrated in FIGS. 20-23.First, as illustrated in FIG. 20, the straps 190 are released, forexample, by cutting which allows the cover member 160 to be lifted offand the walls 180 lifted out of the slots 139 in the base side members130. The walls 180 are then separated and removed as illustrated in FIG.21. The freestanding device 10 is simply supported by the base structure110. A pallet jack or the like is then used to lift the center deck 112as previously described with reference to FIG. 15. Once the legs 14clear, the base side members 130 are easily removed and the device 10lowered until the legs 14 are on the floor as illustrated in FIG. 22.Referring to FIG. 23, the center deck 112 is then removed. The processdescribed with reference to FIGS. 24 a-24 h may be utilized ifnecessary. The device 10 is easily unpackaged without any tools otherthan a tool used to remove the straps 190.

These and other advantages of the present invention will be apparent tothose skilled in the art from the foregoing specification. Accordingly,it will be recognized by those skilled in the art that changes ormodifications may be made to the above-described embodiments withoutdeparting from the broad inventive concepts of the invention. It shouldtherefore be understood that this invention is not limited to theparticular embodiments described herein, but is intended to include allchanges and modifications that are within the scope and spirit of theinvention as defined in the claims.

What is claimed is:
 1. A pallet base structure comprising: a center deckdefining a support surface extending laterally between opposed sides, atleast two lugs extending from each of the opposed sides; and a pair ofbase side members, each base side member having first and second spacedapart base legs and a support member extending between the base legswith at least two corresponding lug receiving slots defined in thesupport member, wherein each of the base side members is positionedalong a respective side of the center deck and the respective lugs arereceived in the respective lug receiving slots such that the center decksupport surface is aligned with an upper surface of each support memberto define a planar pallet surface.
 2. The pallet base structure of claim1 wherein each lug has a dovetail configuration and each lug receivingslot has a corresponding dovetail configuration.
 3. The pallet basestructure of claim 1 wherein the at least one of the lugs on one side ofthe center deck is longitudinally offset from a corresponding lug on theopposite side of the center deck.
 4. The pallet base structure of claim1 wherein three lugs extend from each side of the center deck andwherein a forward most lug a first of the sides of the center deck islongitudinally aligned with a forward most lug on the opposite secondside of the deck and the remaining lugs on the first side of the centerdeck are longitudinally offset from the remaining lugs on the secondside of the center deck.
 5. The pallet base structure of claim 1 whereineach lug has a height less than a height of the center deck.
 6. Thepallet base structure of claim 1 wherein each base side member has alongitudinal space defined below the support structure between the baselegs.
 7. The pallet base structure of claim 1 wherein each base sidemember includes a shock dampener on a lower surface of each base leg. 8.The pallet base structure of claim 1 wherein each support member definesat least two spaced apart leg receiving openings.
 9. The pallet basestructure of claim 1 wherein each base side member includes a side wallextending up from the support member.
 10. A pallet base structurecomprising: a center deck defining a support surface extending betweenopposed sides; a pair of base side members, each base side member havingfirst and second spaced apart base legs and a support member extendingbetween the base legs; and at least two connection members, eachconnection member configured to releasably connect a respective baseside member with the center deck such that the center deck supportsurface is aligned with an upper surface of each support member todefine a planar pallet surface.
 11. The pallet base structure of claim10 wherein the connection members are selected from the group comprisingclamps, screws, pegs, dowels and lugs.
 12. A packaging system comprisinga pallet base structure according to claim 10, a cover member configuredto be positioned spaced from the pallet base structure, and at least onestrap member configured to extend about the pallet base structure andthe cover member such that the pallet base structure and the covermember are an interconnected unit.
 13. The packaging system of claim 12wherein at least one strap receiving slot is defined across a lowersurface of the center deck, along each of the base side members, andacross a top surface of the cover member.
 14. The packaging system ofclaim 12 wherein the cover member includes a planar portion and a raisedcenter portion defining a concave internal space.
 15. The packagingsystem of claim 12 further comprising a wall system configured to besecurely positioned between the pallet base structure and the cover. 16.The packaging system of claim 15 wherein the pallet base structure andthe cover each define wall receiving slots.
 17. A method of packaging afree standing machine comprising a housing supported on a plurality ofspaced apart legs such that a lower housing surface is supported spacedfrom a ground surface upon which the legs are supported, the methodcomprising: positioning a center deck below the lower housing surfacebetween the machine legs, the center deck having a support surfaceextending between opposed sides; raising the center deck such that thecenter deck contacts the lower housing surface and raises the housinguntil the legs are spaced from the planar surface; aligning a base sidemember adjacent each of the center deck opposed sides, each base sidemember having first and second spaced apart base legs and a supportmember extending between the base legs; lowering the center deck untilthe center deck support surface is aligned with an upper surface of eachsupport member to define a planar pallet surface; and releasablyconnecting each base side member to the center deck such that therelative position of the center deck support surface to the uppersurface of each support member is maintained and the machine legs aremaintained spaced from the ground surface.
 18. The method of claim 17wherein each support member defines one or more leg receiving openingsand during the lowering step, each of the machine legs is received in arespective leg receiving opening.
 19. The method of claim 17 furthercomprising: positioning a cover on a top surface of the machine housing;and securing at least one strap about the cover, the center deck andeach base side member.
 20. The method of claim 19 further comprisingpositioning a wall system between the cover and the base side membersbefore securing the at least one strap.